Motor generator system driven by V-belt

ABSTRACT

A motor-generator system for a vehicle, in which power transmission between a crankshaft of an engine and a motor-generator is performed by a V-belt wound around pulleys thereof, includes a speed controller controlling the rotational speed of the V-belt within a predetermined range and provided on a crankshaft pulley mounted on the crankshaft. The motor-generator system, among others, can maintain the power transmission force of the V-belt at a high level.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional application of U.S. application Ser.No. 12/503,163, filed Jul. 15, 2009, which claims under 35 U.S.C.§119(a) of Japanese Patent Application No. 2008-312101, filed Dec. 8,2008, the entire contents of which are incorporated herein by reference.

BACKGROUND

(a) Technical Field

The present disclosure relates to a motor-generator system driven by aV-belt. More particularly, it relates to a motor-generator system drivenby a V-belt, which improves power transmission efficiency using a speedcontroller controlling the rotational speed of the V-belt.

(b) Background Art

An example of a typical V-belt is shown in FIG. 5. A V-belt 6 isconnected to a crankshaft pulley 1 of an engine 5, a motor-generatorpulley 2, a water pump pulley 3, and a compressor pulley 4. When acrankshaft of the engine 5 rotates, the power of the engine 5 istransmitted to the water pump pulley 3 or the compressor pulley 4 asauxiliary equipment by the V-belt 6. A motor-generator comprises anelectric motor and an electric generator. The electric motor rotates themotor-generator pulley 2 to start the engine 5. During traveling of avehicle, the power of the engine 5 is transmitted to the electricgenerator via the motor-generator pulley 2, and the generatedelectricity is stored in a battery (not shown).

A typical relationship between V-belt speed and transmission force isshown in FIG. 6. As shown in FIG. 6, the transmission force of theV-belt depends on the speed of the V-belt, i.e., the rotational speed ofthe pulley. When the speed of the V-belt is low, i.e., when therotational speed of the pulley is low, the transmission force of theV-belt decreases, and thus it is impossible to provide efficient powertransmission.

A typical relationship between motor rotational speed, torque, andefficiency is shown in FIG. 7. As shown in FIG. 7, the efficiency of themotor is very poor at low speed and high torque. In FIG. 7, if the motortorque is 400 to 500 Nm at a rotational speed of about 250 rpm, forexample, the efficiency of the motor is below 50%. In general, thismotor torque is inevitably used during start-up of the engine, and thusthe load of the battery is increased. Since this low rotational speedcorresponds to a V-belt speed of 2 to 5 m/s, the transmission force ofthe V-belt is as low as 3 kW as shown in FIG. 6.

Japanese Patent Publication No. 2003-42248 discloses a belt tensionadjusting device, which applies a large tension to a V-belt to transmita large transmission torque from a starter motor to a crankshaft of anengine during start-up of the engine and releases the tension after thestart-up is complete. However, although the increase in the tension ofthe V-belt prevents slip between the V-belt and the pulley, it does notimprove the power transmission efficiency.

The above information disclosed in this Background section is only forenhancement of understanding of the background of the invention andtherefore it may contain information that does not form the prior artthat is already known in this country to a person of ordinary skill inthe art.

SUMMARY OF THE DISCLOSURE

The present invention has been made in an effort to solve theabove-described problems associated with prior art. Accordingly, thepresent invention provides a motor-generator system driven by a V-belt,which can maintain the power transmission force of the V-belt at a highlevel

In one aspect, the present invention provides a motor-generator systemdriven by a V-belt and provided in a vehicle in which power transmissionbetween a crankshaft of an engine and a motor-generator is performed bya V-belt wound around pulleys thereof, the motor-generator systemincluding a speed controller controlling the rotational speed of theV-belt within a predetermined range and provided on a crankshaft pulleymounted on the crankshaft.

In a preferred embodiment, the speed controller includes a planetarygear unit disposed between the crankshaft pulley and the crankshaft, afirst clutch directly connecting the crankshaft pulley to thecrankshaft, and a second clutch connecting the crankshaft pulley to theplanetary gear unit.

In another preferred embodiment, the speed controller includes atoroidal converter and a governor controlling the inclination angle of apower roller of the toroidal converter according to the rotational speedof the crankshaft.

In still another preferred embodiment, the governor includes a solenoidformed by winding a coil around a movable core, in which an electriccurrent according to the rotational speed of the crankshaft flowsthrough the coil, and the inclination angle of the power roller iscontrolled by the movable core.

In yet another preferred embodiment, he speed controller furtherincludes a clutch disposed between the toroidal converter and thecrankshaft.

In still yet another preferred embodiment, the speed controller includesa torque converter.

In a further preferred embodiment, the torque converter includes alock-up clutch rotating the crankshaft and the crankshaft pulley at thesame speed.

In another further preferred embodiment, the speed controller furtherincludes a clutch disposed between the torque converter and thecrankshaft.

Other aspects and preferred embodiments of the invention are discussedinfra.

It is understood that the term “vehicle” or “vehicular” or other similarterm as used herein is inclusive of motor vehicles in general such aspassenger automobiles including sports utility vehicles (SUV), buses,trucks, various commercial vehicles, watercraft including a variety ofboats and ships, aircraft, and the like, and includes hybrid vehicles,electric vehicles, plug-in hybrid electric vehicles, hydrogen-poweredvehicles and other alternative fuel vehicles (e.g. fuels derived fromresources other than petroleum). As referred to herein, a hybrid vehicleis a vehicle that has two or more sources of power, for example bothgasoline-powered and electric-powered vehicles.

The above and other features of the invention are discussed infra.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other features of the present invention will now bedescribed in detail with reference to certain exemplary embodimentsthereof illustrated the accompanying drawings which are givenhereinbelow by way of illustration only, and thus are not limitative ofthe present invention, and wherein:

FIG. 1 is a schematic diagram of a motor-generator system driven by aV-belt in accordance with a first embodiment of the present invention,in which a planetary gear unit and a clutch are used in a speedcontroller;

FIG. 2 is a schematic diagram of a motor-generator system driven by aV-belt in accordance with a second embodiment of the present invention,in which a toroidal converter and a clutch are used in a speedcontroller;

FIG. 3 is a schematic diagram of a motor-generator system driven by aV-belt in accordance with a third embodiment of the present invention,in which a torque converter and a clutch are used in a speed controller;

FIG. 4 is a diagram showing power transmission efficiency of the torqueconverter of FIG. 3, in which the vertical axis represents the powertransmission efficiency (η) and the horizontal axis represents the ratiobetween input and output power [n2 (turbine runner speed)/n1 (pumpimpeller speed)];

FIG. 5 is a schematic diagram showing a typical V-belt;

FIG. 6 is a graph showing the typical relationship between V-belt speedand transmission force; and

FIG. 7 is a graph showing the typical relationship between motorrotational speed, torque, and efficiency.

Reference numerals set forth in the Drawings includes reference to thefollowing elements as further discussed below:

 1: crankshaft pulley  2: motor-generator pulley  3: water pump pulley 4: compressor pulley  5: engine  6: V-belt  7: motor-generator  8:crankshaft  9: lock-up clutch 10: first clutch 11: second clutch 13: sungear 14: planetary gear 15: planetary gear unit 16: governor 17:toroidal converter 18: power roller 19a: input disc 19b: output disc 20:clutch 21: torque converter 21a: pump impeller 21b: stator 21c: turbinerunner

It should be understood that the appended drawings are not necessarilyto scale, presenting a somewhat simplified representation of variouspreferred features illustrative of the basic principles of theinvention. The specific design features of the present invention asdisclosed herein, including, for example, specific dimensions,orientations, locations, and shapes will be determined in part by theparticular intended application and use environment.

In the figures, reference numbers refer to the same or equivalent partsof the present invention throughout the several figures of the drawing.

DETAILED DESCRIPTION

Hereinafter, embodiments of a motor-generator system driven by a V-beltin accordance with the present invention will be described in detailwith reference to the accompanying drawings.

FIG. 1 is a schematic diagram of a motor-generator system driven by aV-belt in accordance with a first embodiment of the present invention,in which a planetary gear unit and a clutch are used in a speedcontroller.

A motor-generator 7 and an engine 5 perform power transmission by aV-belt 6 wound around a motor-generator pulley 2 and a crankshaft pulley1. A planetary gear unit 15 including a sun gear 13 and planetary gears14, a first clutch 10, and a second clutch 11 are provided in thecrankshaft pulley 1. The first clutch 10 directly connects thecrankshaft pulley 1 to a crankshaft 8 of the engine 5. Meanwhile, thecrankshaft 8 is connected to a carrier (not shown) that connects theplanetary gears 14. The second clutch 11 connects the crankshaft pulley1 to the sun gear 13. For example, three planetary gears 14 rotating onits own axis and revolving around the sun gear 13 are connected to thecarrier (connecting member) such that, when the sun gear 13 rotatesthree times, the carrier rotates one time. In this case, if the sun gear13 is an input and the carrier connecting the planetary gears 14 is anoutput, the planetary gear unit 15 is a ⅓ speed reducer.

According to the speed controller of FIG. 1, the following controloperations can be performed. (1) During start-up of the engine 5, orwhen the engine 5 rotates at a low speed, the first clutch 10 isdisengaged and the second clutch 11 is engaged such that the rotationalspeed of the crankshaft pulley 1 is reduced and the power is transmittedto the crankshaft 8. That is, the crankshaft 8 can rotate at arotational speed suitable for the low-speed rotation by maintaining thespeed of the V-belt 6 at a high level. (2) When the engine rotates at ahigh speed, the first clutch 10 is engaged and the second clutch 11 isdisengaged such that a shaft of the crankshaft pulley 1 is directlyconnected to the crankshaft 8, thus maintaining the high-speed rotationof the V-belt 6. (3) When the engine is stopped to eliminate unnecessaryidling, for example, the first clutch 10 and the second clutch 11 aredisengaged such that the crankshaft pulley 1 is disconnected from theplanetary gear unit 15 and the crankshaft 8. Therefore, it is possibleto operate auxiliary equipments such as an air conditioner by the powerof the motor-generator 7 even when the engine is stopped.

FIG. 2 is a schematic diagram of a motor-generator system driven by aV-belt in accordance with a second embodiment of the present invention,in which a toroidal converter and a clutch are used in a speedcontroller.

As shown in FIG. 2, the motor-generator 7 and the engine 5 perform powertransmission by the V-belt 6 wound around the motor-generator pulley 2and the crankshaft pulley 1. A toroidal converter 17, a governor 16, anda clutch 20 are provided in the crankshaft pulley 1. The clutch 20connects the crankshaft 8 to the governor 16.

The toroidal converter 17 includes a conical input disc 19 a having acircular arc shaped side, an output disc 19 b having the same shape asthe input disc 19 a, and a power roller 18 connecting the input disc 19a to the output disc 19 b as shown in an enlarged circle of FIG. 2. Theinput disc 19 a rotates and is in contact with the power roller 18 at aposition of radius r1. Then, the power roller 18 rotates and the otherend of the power roller 18 is in contact with the output disc 19 b at aposition of radius r2. Thus, the output disc 19 b is rotated by therotation of the power roller 18. In this case, the transmission gearratio γ is expressed as γ=r1/r2. For example, the power roller 18 isinclined so that r1 is less than r2 (r1<r2), it is possible to use thetoroidal converter 17 as a speed reducer. Moreover, the input disc 19 aand the output disc 19 b are not limited to their input and outputfunctions and may be used bidirectionally.

The governor 16 is a device for inclining the power roller 18. Thegovernor 16 of FIG. 2 is configured by attaching an arm and a weight tothe crankshaft 8. By the arm and the weight, the governor 16 is movedoutward by the centrifugal force according to the rotational speed ofthe crankshaft 8, thus inclining the power roller 18. Alternatively,instead of the arm and the weight, the governor 16 may comprise asolenoid (not shown) in which a current flows according to therotational speed. The solenoid in which a movable ferromagnetic core isactuated by a magnetic field generated by a current flowing through acoil is compact and has a large driving force.

According to the speed controller of FIG. 2, the following controloperations can be performed. (1) During start-up of the engine 5, theclutch 20 is engaged such that the speed of the crankshaft pulley 1 ismaintained constant by the governor 16 and the toroidal converter 17.(2) When the engine 5 is stopped, the clutch 20 is disengaged such thatthe crankshaft pulley 1 is disconnected from the crankshaft 8.Therefore, it is possible to operate auxiliary equipments by the powerof the motor-generator 7 even when the engine 5 is stopped.

FIG. 3 is a schematic diagram of a motor-generator system driven by aV-belt in accordance with a third embodiment of the present invention,in which a torque converter and a clutch are used in a speed controller.

As shown in FIG. 3, the motor-generator 7 and the engine 5 perform powertransmission by the V-belt 6 wound around the motor-generator pulley 2and the crankshaft pulley 1. The crankshaft pulley 1 may include atorque converter 21 and a clutch 20.

The torque converter 21 includes a pump impeller 21 a, a stator 21 b,which directs the oil flow generated by the pump impeller 21 a, and aturbine runner 21 c rotated by the oil from the stator 21 b. Here, thepump impeller 21 a is connected to the crankshaft pulley 1, and theturbine runner 21 c is connected to the crankshaft 8. The oil dischargedfrom the turbine runner 21 c is returned to the pump impeller 21 a viathe stator 21 b to rotate the pump impeller 21 a. Moreover, a lock-upclutch 9 is provided to directly connect the pump impeller 21 a to theturbine runner 21 c as shown in FIG. 3.

According to the speed controller of FIG. 3, the following controloperations can be performed. (1) When there a large speed differencebetween the pulleys during start-up of the engine 5, the clutch 20 isengaged so as to control the speed according to the transmission forceby the torque converter 21. (2) When the speed difference between thepulleys becomes smaller after the start-up of the engine 5, the clutch20 is engaged and, further, the lock-up clutch 9 is engaged. Withoutintending to limit any theory, the reason is that, when speed n1 of thepump impeller 21 a becomes equal to speed n2 of the turbine runner 21 c,the power transmission efficiency η is significantly deteriorated asshown in FIG. 4. Accordingly, the lock-up clutch 9 is engaged to preventthe deterioration of the efficiency. (3) When the engine 5 is stopped,the clutch 20 is disengaged such that the crankshaft pulley 1 isdisconnected from the crankshaft 8. Therefore, it is possible to operateauxiliary equipments by the power of the motor-generator 7 even when theengine 5 is stopped.

As described above, according to the motor-generator systems driven bythe V-belt of the present invention, in which the speed controllercontrolling the rotational speed of the V-belt within a predeterminedrange is provided in the crankshaft pulley, it is possible to maintainthe rotational speed of the V-belt at a high level, even if therotational speed of the engine varies, thus maintaining hightransmission force. For example, during start-up of the engine, themotor-generator is rotated at a high speed and the high transmissionforce of the V-belt is maintained such that the crankshaft can transmithigh torque even at a low rotational speed. Therefore, it is possible toimprove the capability for supporting the motor-generator and improvethe charging efficiency of a hybrid vehicle.

With the use of the speed controller including the planetary gear unit,the first clutch directly connecting the crankshaft pulley to thecrankshaft, and the second clutch connecting the crankshaft pulley tothe planetary gear unit, it is possible to maintain the high rotationalspeed of the V-belt. Moreover, the crankshaft pulley can be disconnectedfrom the crankshaft, and thus it is possible to operate auxiliaryequipments by the power of the motor-generator even during idle stop inwhich the engine is stopped due to temporary parking, for example.

With the use of the speed controller including the toroidal converterand the governor, the rotational speed of the V-belt can be maintainedconstant by the transmission function of the toroidal converter.

Moreover, with the use of the solenoid provided in the toroidalconverter, in which the movable core is actuated by the currentaccording to the rotational speed of the crankshaft flowing through thecoil, it is possible to achieve a compact size and a large driving forcecompared to the case where the power roller of the toroidal converter isactuated by rotating the mechanical weight and using the centrifugalforce.

Furthermore, with the use of the clutch disposed between the toroidalconverter and the crankshaft, it is possible to operate auxiliaryequipments by the power of the motor-generator even during idle stop inwhich the engine is stopped due to temporary parking, for example.

In addition, with the use of the speed controller comprising the torqueconverter, it is possible to maintain the rotational speed of the V-beltconstant by the transmission function of the toroidal converter. Thatis, the torque converter includes the pump impeller, the stator, and theturbine runner such that the turbine runner can be rotated by amplifyingthe torque ratio by, e.g., two times by the oil flow of the stator.

Additionally, with the use of the lock-up clutch rotating the crankshaftand the crankshaft pulley at the same speed and provided in the torqueconverter, the power is directly transmitted, and thus it is possible toprevent the energy conversion loss by the oil.

Besides, with the use of the clutch disposed between the torqueconverter and the crankshaft, it is possible to operate auxiliaryequipments by the power of the motor-generator even during idle stop inwhich the engine is stopped due to temporary parking, for example.

The invention has been described in detail with reference to preferredembodiments thereof. However, it will be appreciated by those skilled inthe art that changes may be made in these embodiments without departingfrom the principles and spirit of the invention, the scope of which isdefined in the appended claims and their equivalents.

What is claimed is:
 1. A motor-generator system for a vehicle in whichpower transmission between a crankshaft of an engine and amotor-generator is performed by a V-belt wound around pulleys thereof,the motor-generator system comprising a toroidal converter and governorcombination including at least one of an arm and weights and a solenoidform by winding a coil around a motor core, the toroidal converter andgovernor combination controlling the rotational speed of the V-beltwithin a predetermined range and provided on a crankshaft pulley, thetoroidal converter and governor combination connecting the pulley to thecrankshaft via a clutch between the engine and one or more components ofthe toroidal converter and governor combination.
 2. The motor-generatorsystem of claim 1, wherein the governor controls the inclination angleof a power roller of the toroidal converter according to the rotationalspeed of the crankshaft.
 3. The motor-generator system of claim 2,wherein an electric current is applied by the governor according to therotational speed of the crankshaft flows through the coil, and theinclination angle of the power roller is controlled by the movable core.4. A motor-generator system for a vehicle in which power transmissionbetween a crankshaft of an engine and a motor-generator is performed bya V-belt wound around pulleys thereof, the motor-generator systemcomprising a torque converter controlling the rotational speed of theV-belt within a predetermined range and provided on a crankshaft pulley,the torque converter connecting the pulley to the crankshaft via aclutch between the engine and one or more components of the torqueconverter, wherein the torque converter comprises a lock-up clutchrotating the crankshaft and the crankshaft pulley at the same speed.